Rajapalayam Textile Mill Visit report for CRP

Process steps

1. After loading 10 Nos of hank yarn in each Batch of one Mercerization machine, immersed in the
15to18 Deg C of 484gpl of Caustic solution.
2. After mercerization process, Control system will stop the process and drain the diluted caustic lye
into the Eco block as per the programed sequence. Eco block is the 1 KL storage tank and Control
system is monitoring the Caustic concentrations in the tank and based on the requirement
automatically top up the fresh and recycled caustic solutions to maintain the Caustic
concentrations. Every week its disposed (25 KL/week) based on the caustic quality and shrinkage
of yarn quality and every day 800 KL of fresh caustic lye are consumed and cost of caustic lye is
22~41 INR/Kg.
3. Caustic mercerized yarn shall be washed so first wash with 85Deg C hot water then after washing
its shall be drained and collected in the CRP feed tank.
4. CRP system consist of collection tank and fine screen then feed to the multiple evaporators ( 2
falling film and one forced circulation) for increase the concentration from 40~88 gpl to
296~484gpl. They are reusing back 3KL/day of 484gpl solution for mercerization process.
Evaporator condensate water (30.5KL/day) reused for process.
#CRP operational cost is 4 INR/ kg of yarn and 2400 Kg of Yarn per day is processed in one
machine.

#CRP operational cost : 9600 INR/day

# Evaoprator cleaning cost: 25000INR /each time ( Yearly twice)

 # Every day operation is 20 Hours and remain 4 hours hot water flushing

# Effluent generation for CIP/flushing is not measured and it’s going to ETP.

5. Next washing will be carried out with 50Deg C and after washing, washed water pumped to 85Deg
C water storage tank, so caustic recycle is increased by using this method.
6. Next washing will be carried out with 20 Deg C RO water and after washing drained water is
pumped to 50 DegC Storage tank to reuse.
7. After completion of the total process, machine automatically unlocked and opened, and hank is
removed manually and fixed in the neutralization machine. Water and acetic acid are used for
neutralization process. Drained water pumped to ETP.
8. After neutralization, manually feeded to the drying machine to dry the moisture.

Note:

1. They have one machine and they are planning to install next two machine in same building
and same capacity, so they are looking for OEM with complete solutions of CRP. Existing plant
was installed by ATE; Mumbai based company.
2. Weekly once 25 KL of 296 gpl caustic solution is disposed and only they are paying for
transportation charges only and diluted caustic is used for other applications like paper/soap
oil industries.
3. If the colour is improved in the caustic solution, it will be increased for recyclable quantity so
Fresh lye consumption and disposal quantity will be reduced.
4. Requested customer to analysis the CRP diluted lye solution from machine to propose the
pretreatment with membrane technology